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MAY 2018 | Manufacturing Today



Jayashree Kini Mendes

Mitalee Kurdekar

INDIA NEEDS TO CREATE MORE MANUFACTURING jobs. That has been a constant refrain of Prime Minister Modi. The loss of manufacturing jobs has been a problem for several countries around the world. Probably, India can take a cue from how Germany has made manufacturing its forte and continues to maintain this industry as a large scale contributor to its economy. Similarly, Vietnam has carved its own niche. Worldwide, one in 10 smartphones is manufactured in Vietnam. The country generates export revenues of more than $45 billion from exports of smartphones alone. Yet another country that has the fastest growing economy is Nevada and it is manufacturing that is driving its growth. Advanced manufacturing is fast remaking the world of production. For long, productivity has been the gauge by which the health of the manufacturing industry has been measured; but in these transformative times, productivity alone does not tell the whole story. Indeed, as revolutionary technologies like cloud, artificial intelligence, robotics, augmented reality, and 3D printing increasingly take hold, it can be argued that innovation and digital transformation will be the benchmarks of the future. It is in this light that Manufacturing Today is organising Smart Manufacturing Summit 2018, or SMS as it is better known now, a full day event, that will be held in Gurgaon on June 8. In its 3rd edition, SMS will go back to what was spoken earlier and unearth how much of that has changed. The idea is to help large and midsized companies to fully understand what exactly they can do with their assets and how they can transform them. No more will production continue to be a routine. There are exciting things to explore and and if companies can put their mind (and heart) into it, they can make manufacturing one of the most exciting professions to be in.

Jayashree Kini-Mendes Editor


Volume 8 | Issue 05 | May 2018

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Please provide your full name and address, stating clearly if you do not wish us to print them. The opinions expressed in this section are of particular individuals and are in no way a reflection of the publisher’s views.


MAY 2018 | Manufacturing Today

Published by and © 2018 ITP Media (India) Pvt Ltd RNI No: MAHENG/2011/37959


What Connected Technologies and Strategies are Right for You? Smart manufacturing and industrial operations embrace a new way forward. This new direction is highly connected so devices and processes can be continually monitored and optimized.

ADVISORY BOARD Our distinguished advisory board has been assembled to help guide Manufacturing Today to become even more representative of its community. Members have been invited from the highest levels of the industry to ensure that the magazine continues on its path of success.

Aman Chadha, Chairman, EEPC India (Also MD, Nikko Bearings)

Anant Sardeshmukh, Executive Director, General, MCCIA

Kishore Jayaraman, President, Rolls-Royce South Asia

Manish Kulkarni, Director – Strategy & Business Development BDB India

N Tarachand Dugar, President, All India Manufacturers’ Organisation (Also chairman, Dugar Group)

Pradeep Bhargava, Director, Cummins India

Raj Singh Rathee, Managing Director, KUKA Robotics India

Rajesh Nath, MD & CEO, German Engineering Federation (VDMA), India

Robindranath Som, President, Nickunj Eximp Enterprises

Satish Jamdar, Chief Mentor and Advisor, American Vision

SM Bhat, Managing Director, Ador Welding

Dr. Wilfried G Aulbur, Managing Partner, India, Chairman, Middle-East, Head, Automotive Asia, Roland Berger Strategy Consultants

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MAY 2018 | Manufacturing Today



The agreement was signed at Defexpo. Rolls-Royce and Goa Shipyard Limited (GSL), a premier defence shipbuilding yard in India under the Ministry of Defence, have agreed to cooperate in the local manufacturing of technologically-advanced MTU Series 8000 engines in India. Under the agreement, which was signed at India’s leading defence trade show Defexpo, the companies will assemble the 16-cylinder and 20-cylinder MTU Series 8000 engines at GSL’s new facility in Goa. The MTU brand is a worldwide leader

in large diesel and gas engines and complete propulsion system, and part of Rolls-Royce Power Systems. The agreement includes transfer of MTU technology related to localising of engine components, engine assembly, testing, painting and major overhauls. MTU Series 8000 engines are the largest and most powerful MTU diesel engines with a power output of up to 10 MW. They are fitted onboard all Offshore Patrol Vessels (OPV) recently constructed or currently under construction in India. This includes eleven Coast Guard OPVs by GSL (six completed and five under construction), five Naval OPVs under construction at Reliance Defence Engineering, and seven Coast Guard OPVs by L&T. The new facility will also undertake all major overhauls of these engines.

VEDANTA RESOURCES PLC APPOINTS CEO AND EXECUTIVE DIRECTOR Vedanta Resources plc has appointed Srinivasan Venkatakrishnan (Venkat) as CEO and a member of the Board of Directors, effective August 31, 2018. He succeeds Kuldip Kaura, the current Interim CEO. Since 2013, Venkat (53) has been CEO of AngloGold Ashanti Limited, the world's largest emerging market gold producer. Between 2005 and 2013, he was AngloGold Ashanti's CFO and prior to this, he was CFO of London-listed Ashanti Goldfields Limited. Anil Agarwal, chairman of Vedanta, said, "We have gone through a very thorough search process and are delighted to invite Venkat to join Vedanta in the position of CEO. Venkat is a widely respected business leader in the global resources space, who brings to Vedanta an impressive set of values and a wealth of experience in corporate and


MAY 2018 | Manufacturing Today

other roles in the UK, Africa, Australia, South America and India. He also has a strong track record managing a complex portfolio of operating assets and projects across Africa. He has proved his ability to deliver significant operating and financial improvements, while also ensuring important advances in sustainability. The team at Vedanta and I are very much looking forward to working with him. We are grateful to Kuldip Kaura for his support during the interim period; he will continue as interim CEO until Venkat joins." Venkatakrishnan stated, "My initial focus will be to ensure continued operational excellence, efficient cost management and capital discipline across the portfolio, while continuing to drive improvements to the overall sustainability performance of the business, thereby creating long-term value for all stakeholders."

STERLING AND WILSON FORAYS INTO HYBRID POWER PLANTS AND ENERGY STORAGE SOLUTIONS Sterling and Wilson has announced its foray into hybrid power plants and energy storage solutions as part of its commitment to consistently expand its range of offerings to reflect the future of energy. The company, with a cumulative expertise of 8 GW across its energy verticals encompassing co-generation CHP and gas-based power, solar energy and diesel powered generators, is poised to lead the disruptive revolution of energy storage besides fostering adoption of clean energies by critical power installations through hybrid power plants. The newly introduced hybrid and energy storage business is already in advanced discussions for its first projects in Africa and Europe, and is keenly exploring EPC and co-development opportunities across continents. Sterling and Wilson’s strong intent to invest in the hybrid and energy storage space is backed by a visible global trend of ever increasing need for reliable power and a strong endorsement by developed economies to reduce carbon emission, within a $6 trillion global energy industry that is ripe for disruption. To lead the charge amidst such trends, the company has appointed Deepak Thakur at the helm of its hybrid & energy storage business as the CEO. With an experience of 26 years and a proven track record of incubating new businesses from strategy to building strong teams, Thakur has successfully handled various responsibilities encompassing sales, marketing, corporate strategy, business planning and strategic alliances across a wide spectrum of industries. Further, by tapping into its internal talent pool, the company has also appointed Vishwanathan Iyer to lead the global business development, marketing and strategic activities for the new unit.

Your Wisdom Makes It Smart Automation for your Smart Manufacturing By implementing our expertise in the smart production line, Delta realizes smart manufacturing, in customized as well as mass production, to put intelligence into production and let manufacturing respond to human nature. |



This first locomotive is part of a €3.5 billion order comprising 800 electric double-section locomotives. Alstom announced the completion of its first all-electric locomotive from its state-of-theart locomotive facility at Madhepura in the state of Bihar, on schedule. In line with the Government’s and Indian Railways’ target towards 100% electrification and towards sustainable mobility, these new locomotives will not only bring down operating costs for the Railways, but will significantly cut down greenhouse gas emissions as well. This first locomotive is part of a €3.5 billion order comprising 800 electric doublesection locomotives signed in 2015, which contributes to the Ministry of Railways’

public-private partnership programme to modernise the country’s rail infrastructure. This agreement remains the largest Foreign Direct Investment in the railways sector to date, and has a strategic role in creating a multiplier effect on the economy. This contract is also one of the biggest contracts in the history of Alstom. Henri-Poupart Lafarge, chairman and CEO, Alstom, said, “This project stands as a shining example of Alstom’s commitment to Make in India. Apart from creating thousands of jobs directly and indirectly, we have created a strong localised supply chain for this project, with 90% of the components for the prototype sourced locally.” In another significant development, Alstom announced three new contracts worth approximately €75 million – power supply contract from the Mumbai Metro Rail Corporation Ltd (MMRCL), contract for new train sets from Chennai Metro Rail Corporation, and another power supply contract from Jaipur Metro Rail Corporation. This development shows Alstom’s growing footprint in the country, in both the urban space as well as the mainline space.

BREMBO CELEBRATES 10 YEARS OF OPERATIONS IN INDIA AND BUILDS A NEW PLANT IN CHENNAI The year 2018 is set to be a very important year for the growth of Brembo operations in India, wherein the company is working exclusively for the two-wheeler market, driven by the recent introduction of new safety regulations that require the use of higher performance braking systems on all small- and large-engine motorcycles sold in the country. In fact, in addition to celebrating ten years of production presence since the acquisition, in 2008, of all the shares of the Indian KBX Joint Venture from Bosch, Brembo Brakes India – a subsidiary of Brembo SpA – has announced the beginning of work to build a new plant in Chennai for motorcycle braking system assembly. Brembo, which operates in India with the ByBre (By-Brembo) brand developed for the mass market and already boasting more


MAY 2018 | Manufacturing Today

than 50% of the market share in the twowheeler segment, anticipates further growth due to the Indian government's introduction of new legislation which, from next month, will make combined braking systems (with front disc and rear drum) mandatory for vehicles with engine displacement lower than 125cc, as well as ABS, which Brembo will integrate into its braking systems on all vehicles with engine displacement over 125cc. Construction of the new plant, which will be completed within the year and which falls under the 2018 investment plan of about €9 million that the company has launched for process expansion and innovation in the existing Chakan (Pune) and Manesar plants, will allow Brembo to further consolidate the quality of the ByBre brand products and technical collaboration with customers in the Chennai region.


Bosch Power Tools India has launched its ‘Service on Wheels’ – a first-of-its-kind service initiative in India in association with its partners to visit users. The Bosch ‘Service on Wheels’ has been conceptualised to demonstrate the uncompromised and unparalleled best-in-class service experience at their users’ doorstep, coupled with a focus to reduce downtime. Two vans were unveiled at an event in Bengaluru by Henning von Boxberg, president, Bosch Power Tools GmbH.

With a commitment to meet India’s rising power demands, NTPC has announced the commissioning of the first unit of its 2x660 MW super-critical Meja thermal power project. A joint venture between NTPC and the Uttar Pradesh Rajya Vidyut Utpadan Nigam (UPRVUN), the Meja Urja Nigam Private Limited (MUNPL) successfully achieved its full load of 660 MW from its first unit. With this announcement, NTPC’s total power generation stands at a record of 53,651 MW.

Hitachi and Hitachi India have announced that as of April 9, 2018, they have formed Hitachi MGRM Net to expand their social innovation business in India, using digital technologies. Hitachi India acquired part of the shares in MGRM Net, which is involved in the IT service business in India. Consequent to this acquisition, the name of the company would be changed to Hitachi MGRM Net.






MAY 2018 | Manufacturing Today



million vehicles sold globally in Q1 2018.

Manufacturing Today | MAY 2018


COVER STORY VOLKSWAGEN INDIA 1. Robots weld the underbody before it moves to the assembly line. 2. VW India also makes 1.5l and 2.0l engines at the Chakan plant.

HERBIE, A VOLKSWAGEN BEETLE WITH A mind of its own in a series of Disney films launched in the 1960s, had its share of rollercoaster rides. But things had a way of ending up happily for both the car and its passengers. In India, and globally, Volkswagen too has had its fair share of such rides. But this story is about how the company, given its indestructible brand image and a 'people's car', has reinvented itself with more superior vehicles in the last few years. The figures speak for themselves. In March alone this year, globally, the Volkswagen Group delivered 1.04 million vehicles, and over 2.6 million vehicles in Q1 2018. Volkswagen has a new focus now. The Group is driving forward with the transformation to emobility. It has empowered 16 locations around the world to produce battery powered vehicles by the end of 2022. It is typical for an automotive company to come up with new products regularly, sometimes with cosmetic changes and other times a new variant. Speaking about how the company looks at technological changes, Dr Andreas Lauermann, president & MD, Volkswagen India, says, "Change is constant. Over the years, I have witnessed so much of technology changes and there's more or less a cycle time of seven years. But when you compare the new technologies to the earlier cars, you come to understand that underneath all this lies one fact, Safety." This is a core focus for the company. Safety does not stop at mere airbags. It starts with the structural rigidity of the car body itself. Volkswagen is represented in India with five pas-

senger car brands: Audi, Lamborghini, Porsche, ŠKODA, and Volkswagen, and run several models in each brand. From the technology point of view, a passenger car was always driven by the engine, the metal sheets and the interiors. Over the years, the dynamics of this too has changed. "Now you have different influences coming up. The engines, the mobility, the connectivity, are all changing and with it the total business model has to change. The influences are not only from the core of a car, it’s more of the surrounding technologies which has to do with software," adds Dr Lauermann. It is precisely for this reason that the team in India is a strong believer of innovation. He says, "As a German




MAY 2018 | Manufacturing Today


company, few know about the innovation or technology enhancements happening in India. As a manufacturer, one has to create a culture where people question the routine work they do so that they can change the way they work and come up with novel ideas. We have created such a culture among our people, which leads to a healthy competition internally." HIGHLY CHARGED AMBITIONS Volkswagen India believes that thoughfulness in every act leads to a larger change. Interestingly, any innovation emerging from India finds an application globally across the Group plants. It has also established a global knowledge-sharing platform wherein each of its plants share its best practices for other plants to adopt. So, every other factory is able to innovate ways of eco-friendly manufacturing and also use the knowledge from others. Furthermore, the Volkswagen Pune plant has lined up projects for 2018 to make its plant even more efficient in terms of effects on environment. “Our focus is not only on manufacturing great cars but also on how we manufacture them. Our aim is to produce cars in the most

3. Safety is not confined to airbags alone. VW Group believes that a rigid structure must first be made.



MAY 2018 | Manufacturing Today


environment-friendly way,” says Dr Lauermann. The Pune plant is one of the 27 Volkswagen automotive manufacturing facilities worldwide that follows the ‘Think Blue. Factory.’ initiative that aims towards achieving higher environment-friendly manufacturing.This programme measures impact of manufacturing on environment in five key areas: energy consumption, CO2 emissions, water consumption, waste generation and solvent emissions and aims at achieving a reduction of 45% by 2025. The results (reduction per car produced) by the end of 2017 as compared to the base values from 2011 are: Energy consumption reduced by 30.8%, CO2 emissions reduced by 31.7%, water consumption reduced by 46.9%, waste generation reduced by 39.4%, and solvent emissions reduced by 6.8%. A major project under the ‘Think Blue. Factory.’ programme at the Pune Plant yielded sizeable results last year


Why do you have to love this length gauge? There are some things in life that you can love from the very first moment. For example the CERTO length gauge from HEIDENHAIN. Once you’ve decided in its favor, you’re likely to stay with it forever. Regardless of the application. With its extremely high accuracy, the CERTO length gauge ensures traceability to valid standards — and that even over large measuring lengths of 25 or 60 millimeters, and with a very low measuring uncertainty of up to +/– 50 nanometers. You can always rely completely on the CERTO. And that’s exactly what makes it so loveable. HEIDENHAIN OPTICS & ELECTRONICS INDIA PRIVATE LIMITED, Citilights Corporate Centre, #1, Vivekananda Road, Off Spurtank Road, Chetpet, Chennai 600031, India Phone: +91 44 3023 4000, Web:, Email:; angle encoders

linear encoders

contouring controls

digital readouts

length gauges

rotary encoders

Incremental length gauge


4 & 5. As the car moves on the line, various components such as chassis, electricals, dashboard, windscreens, are fitted onto the structure. 6. The novel Single Stage base coat application has helped save in terms of VOC reduction, structure improvement and also money.

GAINING GROUND In recent times, Volkswagen has created waves with some new variants. In March, the German auto major unveiled a new version of the popular hatchback Polo with a 1.0 lite MPI engine. The 1.0 L MPI engine Polo will generate a peak power of 56kW and a torque of 95Nm. With this, the company enhanced its brand proposition, providing a diverse portfolio to India's carbuyer, with multiple engine options. Last month, its un-




where heat is recovered from exhaust gases. The exhaust gases from the primer oven in Paint Shop are being tapped and the energy from these gases is being used to heat ambient air supplied to air supply unit in the paint booth – a classic case of recycling energy that is otherwise lost. The sustainable results of this project were achieved by generating hot water using the exhaust flue gases which are vented out at 3200 Centigrade. This hot water is then used for heating application in pre-treatment process in the Paint Shop itself. As a result, 80% reduction of hot water generation for this purpose was achieved that helped save 492,483 SCM of Natural Gas consumption and 37MWh/a of electricity as well as reduced CO2 emissions by 1013 tons/a. Through this initiative and many others, Volkswagen aims at reducing the impact of its production process on the environment by 45% per car globally. Volkswagen Pune Plant has been working towards these goals since 2012 and has achieved 31.1% reduction already.

MAY 2018 | Manufacturing Today




*Base coat is applied in two stages (BC1 & BC2). Total robots used: 09 *Degrade mode robotic painting not possible in BC2; leads production loss during breakdown in BC2. *High maintenance & utility required for operating 9 robots *High consumption of paint and bell cleaning thinner required *More consumables needed to maintain the robot *Extra man hour required for maintenance & cleaning purpose

*Base Coat to be applied in single stage (BC1): Total robots used: 6 *Modification in base coat paint & paint application parameter to meet requirement for single stage painting. *Modification in robot programming & PLC Logic for model detection for single stage application. *Trials & validation by cross functional team.

STAGE - 1 *Fender, doors & quarter panel *A zone of the car body *Bonnet, roof & tail gate

STAGE - 2 Apply 2nd coat on fender, doors, quarter panel, vertical area of tailgate *Apply 2nd coat on bonnet, roof & tail gate

STAGE - 1 *Fender, doors & quarter panel & vertical portion of tail gate *Fender second coat, roof & horizontal & vertical portion of tail gate

UNIQUENESS OF NEW PROCESS: * The new single stage is first of its kind & not in use anywhere globally. * Initiative of Blue factory vision - VOC reduction of 16 tonnes/year * Reduction in dust count on car body * Cost saving of 0.33 million â‚Ź/year due to single stage painting * Less maintenance cost (less part replacement & spare part inventory) * Increased productivity (less breakdown as compared to two stage BC).

7. The Paint Shop is one of the most novel and uses a total of 6 robots from 9 earlier.


MAY 2018 | Manufacturing Today

veiled its fully-electric super sports car, the I.D. R Pikes Peak. It comes with 500kW (680 PS), 650Nm of torque and weighs less than 1,100kg. Joining the Polo Pace and Vento Sport editions introduced last month, Volkswagen India launched the Ameo Pace special edition. The company's website indicates that the Volkswagen Ameo Pace edition price is for the top-end Highline trim of the subcompact sedan and is offered with few exterior and interior feature upgrades. Additions include the carbon-fibre finished rear spoiler, black finished outside rear view mirrors (ORVMs), new alloy wheel design and cruise control. Such moves only speak of the company's ability to act fast considering the rapid changes across the industry coupled with a strong focus on R&D. Ask Dr Lauermann about how he discerns what works and what does not in terms of new models, and he says, "The automotive business is quite complex in that one has to constantly refresh with new models if one is to stay connected to different markets. We may not have domination in some markets, but as a manufacturer we must stay aware from the technology point, besides knowing what customers like so that the message can go out loud and clear and also offer us economies of scale." The challenges in India, he says, are different. While as a Group, Volkswagen is clear about what it wants to do, there are internal demands since it is dealing with a young group of people. "We have to speed up on our improvements and reach the level of what is expected from us by the Group. The other challenge is tweaking the vehicles for the Indian market since, obviously, we cannot bring in the same models we have internationally. So there are several changes that need to be made in-house here," he adds. INDIA-CENTRIC PLANS The ethos of change reflects in its concern for region-




alisation strategy, which is to empower the regions. The Group is aware that though it has a strong presence in India, there is an insufficient engineering presence. If all goes well, India might soon become the hub of engineering for Volkswagen globally. In 2015, when Dr Lauermann was appointed president & MD for the India office, his first instinct was to understand the people and their choices. That has held him in good stead. "India is one of the most competitive markets in the world. Unlike in other countries, the experience of selling a car here is different. A thorough market study is what one must do if you have to localise," says Dr Lauermann. As of now, 80% of the content for three of Volkswagen cars is made in India. The company still imports the engines and transmis9 sions, which are then assembled at the Chakan plant in Pune. The idea is to manufacture the powertrains at Pune which will then push the localisation to 90%. The facility uses futuristically designed state-of-the"Though we have a strong supplier base here, we art equipment. For example, the body shop uses the have to weigh the additional parameters of choosDiode Laser Brazing (DLB) technology, whereas the ing suppliers with capabilities of engineering so that Roof & Side Framer laser technology is used for weldthey can develop a new product ing the roof to the body of the car. and also be a partner for the bigger systems. Since we also export ALL IN A DAY'S WORK cars from India, we have to consider Volkswagen India does a lot of things cars is the total capacity of the Volkswagen Pune plant. the supplier base carefully for all our right. At its Academy in Chakan, technimodels," he adds. cal and non-technical training is provided The Pune plant has a manuto service brands and channel partners. facturing capacity of 550 cars per day (in three-shift It offers training in many areas, just to mention a few system) and currently manufactures the Volkswagen — sales, after-sales, soft skills, IT, soft & behavioural Polo, Ameo and Vento, and the ŠKODA Rapid. The aspects, mechatronics, and other technical areas. Aurangabad plant assembles various premium and Dr Lauermann is not resting on his laurels. “Havluxury models of Audi, ŠKODA and Volkswagen sold ing completed 10 years in India tells you about our in India and has an annual maximum capacity of apdedication and working at giving people the car they proximately 89,000. It is the only German car manuwant. Now that we have established ourselves, it is facturing plant in India that covers the entire productime to move to the next step. The German philosotion process from pressing parts to final assembly. In phy is to make things work and we are doing everyaddition to the cars, 1.5-litre and 2.0-litre diesel enthing on our part to involve India into the larger part gines are also assembled at the facility. of the German plan."


8. An aerial view of the VW Chakan plant in Pune. 9. Under 'Think Blue. Factory.', the Heat Recovery Unit saved 80% reduction of hot water generation.

Manufacturing Today | MAY 2018





MAY 2018 | Manufacturing Today


Manufacturing Today | MAY 2018



“SKF is now transitioning from a component manufacturer to a more value-centric proposition for its discerning customers.” – Carl Orstadius

1. Customers in the manufacturing sector are fastidious regarding the quality of bearings as they use them in high-end precision machines or original equipment.

RIGHT FROM HIGH-END AUTOMOBILES TO wind turbines, industrial bearings find use in a large number of applications. In short, these anti-friction components are seen wherever there are products with moving parts that require smooth performance, making them a unique component because of their universal relevance. Repetitive demand is yet another feature of the industrial bearings market. While most industrial bearing products are of a standard type, their lifespan depends upon actual wear and tear within the moving parts of the products in which they are used, and hence cannot be directly linked to the lifespan of products or machines. As a result, the market always generates a consistent after-sales or replacement demand. Such aftermarket demand is prevalent largely in the automotive and industrial segments, wherein one notices a large consumption of industrial bearings. The Indian bearings industry, which comprises of large- and medium-scale manufacturers, is no exception to the above norm, in the sense that almost half its demand comes from the automotive segment. Also, after a slight slowdown, the recent spurt witnessed in the automotive industry’s growth has further escalated the demand for bearings. With an increase in general purchasing power and shift in middle- and lower-income group income levels, the demand for both two-wheelers and four-wheelers has been steadily rising in the past few years.

Thus, this has helped the industrial bearings market demand immensely within India. With initiatives like Make in India and the overall special emphasis laid on the manufacturing sector by the Indian Government, the demand for bearings from the industrial segment is also large, and growing. Given this scenario, many global players have already set up their manufacturing units in the country in order to take advantage of the growing Indian market. This has had a positive impact on the quality of such products being consumed locally, while also setting India up to become an exporter of these goods. In fact, with the quality of bearings being imperative, particularly for unhindered operations and high-uptime of user machines, market competition is focused less on price competition, and instead is largely based on value differentiation in the marketplace. Of course, this happens to be a rather distinctive feature of the otherwise pricesensitive Indian market. DEMAND-DRIVEN MARKET As a matter of fact, the Indian bearings market has matured rather well. The most heartening fact about the Indian bearings market is that it is demand that is chasing supply in the marketplace. However, this brings its own set of challenges to the manufacturers and vendors operating in this space. It is interesting to see just how these issues get successfully tackled



MAY 2018 | Manufacturing Today



n Reliable n Versatile n Global


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SPECIAL FEATURE INDUSTRIAL BEARINGS “Our choice is majorly driven by our product performance and business needs. We have a stringent product validation process.” – Rahul Karambelkar

“We also see many Chinese brands entering the Indian market at various price-points, but what is available in the market at low price is not good for heavy-duty application.” – Anand Tawde

2. On average, a Godrej diesel forklift truck typically uses 15 different sizes of bearings.


MAY 2018 | Manufacturing Today

by them, with equal co-operation from quality-conscious customers. As Carl Orstadius, MD, SKF India, says, “Bearings are critical for nearly all motion applications, making it mandatory for all industries using machinery and related motor-driven linkages to use bearings. The Indian Government has given a major impetus to its Make in India campaign, which has in turn given an increasing push to manufacturing, and made it possible for the industrial sector to grow at 3.5%. In addition to this, the Government of India’s ambitious plan for electrification of all vehicles by 2030, both personal and commercial, has challenged bearing companies to come up with innovative solutions for growth and partnerships.” However, even with high demand, things have not been easy for makers of industrial bearings in India. Customers in the manufacturing sector are fastidious regarding the quality of bearings as they use them in high-end precision machines or original equipment where the investment is significant, and use of bad quality bearings could affect the uptime performance and prove costly in the longer term. On this front, Rahul Karambelkar, GM, materials, Bajaj Auto, suggests, “We have various vendors – MNCs with India operations as well as domestic players. They all are very good suppliers in terms of quality and brand. However, our choice is majorly driven by our product performance and business needs. We have a stringent product validation process.” Anand Tawde, AGM, design, Godrej Material Handling Division, Godrej & Boyce Mfg. Co., supports this view. “We are in the business of designing, manufacturing and servicing of forklift trucks, warehouse equipment and various attachments required for material handling equipment. Bearings are an integral part of material handling equipment like forklift trucks. We see many local/regional suppliers operating in this market. They suffice the non-critical and after-market requirements, but are not suitable for OEM requirements as process quality is a major issue. The authenticity of branded bearings is a major challenge to OEMs like SKF and Timken. We also see many Chinese brands entering the Indian market at various price-points, but what is available

in the market at low price is not good for heavy-duty application. We do see niche applications being catered to by global players,” he points out. On average, a Godrej diesel forklift truck typically uses 15 different sizes of bearings. These range from ball, to taper roller, cylindrical roller, needle roller, thrust roller, and self-aligning to slewing bearings, used in various systems of a forklift truck such as the mast and load carriage (lifting system), loadtilting system, drive axle, steer axle, transmission and rotating attachments. 2

CUSTOMER COLLABORATION & HAND-HOLDING Given the fact that each customer has specific needs, there is a lot of exchange that takes place between the OEMs of industrial bearings and their clients, in order to evaluate the suitability of a product according to the purpose that it is required for. Tawde explains, “We involve our partners upfront in the product design. Application layout with load diagram and other relevant details like life expectancy etc. are shared with the bearings partner to ensure that any new design has an apt bearing solution. The key business requirements for procuring bear-


ings are quality, reliability, availability, delivery (TOC/ replenish to stock), and the technical & after-sales support of the bearings partner. The selection of a partner depends on the quality, testing facilities and market performance of product/partner, as well as the criticality of the bearing in the system.” Things are not too different at Bajaj Auto. Karambelkar states, “At Bajaj Auto, we have regular engagements with bearing manufacturers. We involve them early in the product development process. We also engage them in exploring new technologies (like low-friction bearings) and global benchmarking. Our key business requirements of procuring bearings are based on QCD (quality, cost and delivery or capacity) parameters. We have a long-term partnership approach with vendors, and work with long-term commitments. For any new product development, vendor selection is based on our brands and the business plan (product and volume matrix).” Orstadius explains SKF’s strategy in this context. “SKF is now transitioning from a component manufacturer to a more value-centric proposition for its discerning customers. SKF’s Rotating Equipment Performance (REP) provides solutions that would enable customers to maximise performance, reduce the Total Cost of Ownership (TCO) and increase machine reliability.” He adds, “Our India Distribution Centre (IDC) is strategically located in the industrial belt of Maharashtra and in the vicinity of key automobile manufacturers. It is also well connected with the factories to ensure better availability of stocks and to serve the customers at the shortest possible time. The IDC is a world-class facility that helps SKF improve its logistics structure and serve its customers better.”



BUSINESS CHALLENGES, NOT HINDRANCES Despite these improvements, there are some inherent challenges to contend with. One big challenge is the pricing of bearings in India. Though local pricing is lower than similar imported ones, they cannot compete with cheaper imports from China. Therefore, the

Manufacturing Today | MAY 2018



3. Customers are moving towards faster speeds and even greater performance requirements than ever before. 4. One big challenge is the pricing of bearings in India, as they cannot compete with cheaper imports from China.


MAY 2018 | Manufacturing Today


challenge for local manufacturers is to sustain pricing competitiveness. This is attained by volume expansion and competitive material procurement. Customers also have other benefits enticing them to the leading brands in the market. As Orstadius suggests, “Today, with every SKF product, the customer not only buys quality but usually also avails services offered by the manufacturer, like availability of the product, adherence to delivery deadlines and guarantees, service and consulting services. Consequently, it is not a question of how a product is priced, but of the total cost of a solution.” On their part, customers are moving towards faster speeds and even greater performance requirements than ever before. “In such cases where productivity, precision and performance play an important role, it is really all about the best solution for the need, rather than the best price for the need,” believes Orstadius. Tawde provides an important justification from a customer’s perspective, when he says, “Although bearings fall at the bottom of the cost structure of an equipment, its failure can lead to high-cost of repair and heavy downtime of the equipment. From this perspective, bearings are critical when it comes to TCO.” Another cause for grave concern has been spurious or counterfeit products, which cause hassles

for both genuine manufacturers and their qualityconscious customers. Orstadius says, “Counterfeit products are found in all markets and are of all types and sizes, with all premium industrial brands being subject to counterfeit risks. The problem of counterfeit bearings has become more widespread in recent years, and all markets are now susceptible to receiving these unpredictable quality products of brands unknowingly.” He adds, “The financial damage resulting from the counterfeit products is difficult to quantify. All efforts and dedication to improve Overall Equipment Effectiveness and operational costs can quickly change if the customer uses a counterfeit in their operations. If installed in safety critical equipment, counterfeit products may present a great safety risk for people and the environment. SKF shows no tolerance for counterfeit products and works hard to keep counterfeits away from the market. We assist local authorities continuously in taking action against this illegal activity.” All said and done, competition between overseas and local players is helping customers, especially since the competition is based on service parameters rather than just price. Orstadius says it best: Whether the manufacturer is Indian or global, the customer wins.




THE WORLD OVER, THE CONCEPT OF Industry 4.0 is fast gaining momentum. This new, disruptive technology based on digital innovations has recently found its curve of progression and has transformed and reshaped the way things are viewed in the manufacturing segment. According to the International Yearbook of Industrial Statistics 2016 – published by UNIDO – with its ranking going up by three places, India has now been ranked sixth among the world’s 10 largest manufacturing countries. India is no exception to this global trend and is steadily increasing its share of global manufacturing GDP. All leading countries are embarking on major initiatives to promote manufacturing by adopting the advancements in the Internet and information technology arenas. According to IBEF, the Government of India has set an ambitious target of increasing the contribution of manufacturing output to 25% of GDP by 2025, from 16% currently. IoT, being one of the most important aspects of Industry 4.0 for India, is expected to capture close to 20% share in the global IoT market in the next five years. According to the IBEF forecast, the IoT market in India is projected to grow at a CAGR of more than 28% during 2015-20. Further, the Government of India has taken up initiatives such as Green Corridor and Make in India. India has a unique opportunity to innovatively pave its own road to Smart Manufacturing. Industry 4.0 is expected to transform manufacturing in India by

bringing operational efficiencies to manufacturing industries like automotive, electrical & electronics, aerospace, etc. The major area of focus shall be the technological advancement across various industries. IIoT (Industrial Internet of Things), 3D printing, 3D sensors, social software, augmented reality, and location awareness, are considered to usher in the next era of smart production. These automation technologies are collectively moving the manufacturing industry towards the next phase of technological advancement. Against this backdrop and to create more awareness among the manufacturing industry, VDMA is organising a symposium about Industry 4.0 on June 6 and June 8, 2018, in Bengaluru and Pune, respectively. The event would be a confluence of industry veterans, policy makers, academia, and research institutions. Decision makers of VDMA members, IndoGerman companies, and Indian companies from the engineering industry in both the cities are expected to participate. Notable speakers from German and Indian companies would enlighten the audience on various facets of Industry 4.0 – smart factory, digitisation, predictive maintenance, business model/ strategy, and data security. Participation is by invitation only. For details, please email or call +91 033 - 4060 2364.

Manufacturing Today | MAY 2018





MAY 2018 | Manufacturing Today


Manufacturing Today | MAY 2018



“Automation is set to take over highly-repetitive and monotonous jobs, while simultaneously boosting the capabilities of domestic manufacturers.” – Meenu Singhal

“It is important for Indian manufacturing to take a systematic approach while moving in the direction of Industry 4.0.” – Ninad Deshpande

1. B&R Automation's Orange Box helps to effectively get data from machines and securely move it to IT layers or the Cloud.



MAY 2018 | Manufacturing Today

IF A BUSINESS HAS TO SUCCEED, THEN IT has to remain competitive all the time. This is best understood in the Indian business environment, where the market is highly price-sensitive. However, Indian manufacturers have started to become conscious of other requirements like quality, safety and service. Continuous improvement in all these parameters is the norm from a customer aspirations’ viewpoint. The question remains: how does one remain competitive and still differentiate oneself from peers in the market? The answer lies in technology. Technological applications in all areas of product manufacture have become vital to staying ahead. This appetite for technology enhancement and competitiveness gives rise to automation requirements, with robotics being the latest manifestation of the same. Robotic applications are one form of automation where humans are assisted by specially designed robots to undertake mundane, repetitive and sometimes risky or hazardous tasks easily and consistently, with quality performance. Today, we notice that many Indian manufacturers are keenly inviting innovative technologies from overseas partners, collaborators or parent concerns, while many of them are actually seen to be investing in new areas of automation, data analytics using artificial intelligence (AI) and Internet of Things (IoT) support. ADVENT OF ADVANCED AUTOMATION As Takayuki Inaba, MD, NEC Technologies India, points out, “Fourth industrial revolution technologies and the many ways they can interact with each other enhances human performance, and can be used to achieve solutions from the mundane to the marvelous. In the next 3-5 years, automation will be an extension of robotics and can be termed as the next phase of the industrial revolution.” He goes on to add, “The use of robotics will ex-

pand. It will get more sophisticated and adept at complex task performance. With the advent of advanced analytics and data sciences, as in artificial intelligence, it will be possible to automate complex tasks in manufacturing industries that can act intelligently like humans, thus reducing the labour costs. It will help in increasing the worker quality of life as automation will be used to complete the menial and mindless tasks that are normally done by human workers. Also, it will help in reduction of product cost as most of the laborious efforts will be overpowered by automation." Providing a user viewpoint on this new generation technological advancement, Suresh KV, country head, ZF India, suggests, “Industry 4.0 is a buzzword in our industry today, because it has brought in various advanced technological solutions for manufacturing auto parts and components. It has brought together robots, data and connected devices for creating a productive environment. It has also streamlined operations and offered new business opportunities. The digital revolution is transforming industrial technology and heralding unimagined possibilities in terms of technological advances.” Suresh further states, “At ZF, we recognised the importance of Industry 4.0 in the early stages itself. We have been optimising our production operations for years, through systematic digitisation. Collaborative robots are one element of the fundamental restructuring that is already happening in full swing on shop floors in factories around the world.” In fact, such applications are increasingly becoming a part of ZF's manufacturing ecosystem. YuMi, a small-parts assembly robot introduced in 2015 by ABB, which has a payload of 500 g, has been integrated into ZF’s global assembly lines, and helped the company significantly increase productivity. The robot’s arms are padded, and its sophisticated system of sensors helps it to ‘see’ and ‘feel’, enabling it to avoid collisions with its human co-workers. Additionally, it is capable of performing complex assembly routines with the highest precision. In essence, automation is definitely making its presence felt in the manufacturing arena, and is here to stay. Meenu Singhal, VP, industry business, Schneider Electric, agrees that, “Automation is set to take over highly-repetitive and monotonous jobs, while simultaneously boosting the capabilities of domestic manufacturers. It ensures speed, higher precision and zero errors, thereby immensely increasing productivity and profitability.” TIDAL WAVE OF TECHNOLOGY With computer programming developed tremendously, and the help of macros and programming logic, one can replicate human actions for repetitive tasks.

AN INVESTMENT, NOT A COST The decision to go in for advanced automation & robotics applications is not an easy one financially, given that there is significant portion of import-content in building and installing these applications at manufacturing sites in India. Given our traditional approach of looking at return on investment (ROI), especially quick returns as one considers India’s cost competitive environment, the decision can drag into prolonged debate. Gandhi cautions, “Most of the components that go into a robot are in any case imported, and hence

not very significant savings can be expected by local manufacturing, especially until the volumes pick up. Once the volumes pick up, the case to establish factories in India will become much stronger.” Phatak agrees and states, “Technology products have their share of cost, and so do automation & robotics products. However, with direct benefits and given the value proposition, there is always a win-win situation. Automation solutions can be built with optimum cost and higher deliverables. Thus, automation is an investment and not a cost.” Deshpande feels, “Benefits would always be associated with some costs. It is important for Indian manufacturing to take a systematic approach while moving in the direction of Industry 4.0. They should consider placing the solutions around their challenges and take an organised approach.” Sounding positive on this aspect, Suresh proclaims, “Usage of automation & robotics is definitely


“We have been optimising our production operations for years, through systematic digitisation.” – Suresh KV


Therefore, a lot of robotic applications are now being put to use in industries such as automotive, textiles, metalworking including key areas like defence, space and atomic energy, etc., wherein human intervention can be minimised for known reasons. Ninad Deshpande, head, marketing, B&R Industrial Automation, explains, “The use of robots in manufacturing set-ups and shop floors is exponentially increasing, with many speaking of this growth doubling in coming years. Today, the time needed for technology transfer from western countries to India has reduced drastically, and many Indian organisations are already on their path to evaluating & adopting new technologies. India does not want to be known as a low-cost manufacturing hub, but a technologically-advanced, globally-competent manufacturing hub. Adopting next generation automation and robotics solutions is the way forward for these Indian organisations.” There are many application areas for robotic functions, which can be integrated with automation of the manufacturing line. On this front, Ajey Phatak, head, marketing, Beckhoff Automation, says, “Over the next five years, as more and more companies go for customised manufacturing, automation will play a significant role in terms of automated assembly & handling systems, automated testing systems, and automated logistics. There is no doubt that automation will be the basic pre-requisite for higher productivity and has become a necessity for all manufacturing industries.” Sameer Gandhi, MD, Omron Automation, India, is also optimistic about this development, and offers, “Industry 4.0, though in its infancy stage, has been witnessing gradual adoption by some of the progressive manufacturing giants across varied manufacturing industries such as automotive, FMCG, food & beverage, and pharmaceuticals, to name just a few. Based on this current situation, we can say that the automation industry (including robotics) is in the evolution phase. Manufacturers have started understanding its role in attaining compliance with global standards, towards improving operational excellence, to achieve zero defects, and realise productivity and quality improvements, etc.”

“Automation does not imply lesser employment opportunities, because there will always be a need for newer skill sets to use and maintain the automated system and new opportunities will be created.” – Ajey Phatak 4. xxx


Manufacturing Today | MAY 2018



gaining momentum in the automotive industry. Automation & robotic applications are transforming manufacturing facilities into smart & connected factories. Adopting automation & robotics in operations requires initial set-up cost and regular maintenance. These applications demand a lot of capital investment for initial set up. Since automation & robotic applications run on software, regular monitoring and installation of latest software updates is necessary. Though there are certain concerns in adoption, we cannot overlook the ROI that these applications give.”

“Manufacturers have started understanding its role in attaining compliance with global standards, towards improving operational excellence, to achieve zero defects, and realise productivity and quality improvements, etc.” – Sameer Gandhi

“In the digital era, the focus needs to shift from securing network perimeters to safeguarding data spread across systems, devices, and the Cloud.” – Takayuki Inaba 2. Players like Beckhoff believe in developing automation solutions with optimum cost and higher deliverables. 3. Omron feels that once the volumes pick up, the case to establish factories in India will become much stronger.


MAY 2018 | Manufacturing Today

CROSSING HURDLES Implementing robotic solutions and automation applications is no mean task. Besides having initial investment decisions and ROI considerations to tackle with, there are obvious concerns surrounding issues relating to safety in operations, job losses and upskilling of labour. Many users in the manufacturing space have been debating over these issues with their vendors. On their part, vendors are incorporating valid suggestions to make the transfer of technology as smooth as can be. Japan is one country where automation in manufacturing has blossomed so much, that the use of robotics is also significantly high. But India is keen to catch up, and fast. Inaba views these concerns positively, when he says, “As people embrace technologies such as IoT, Big Data, the Cloud, and mobility, security must be more than an afterthought.” He also believes that, “In the digital era, the focus needs to shift from securing network perimeters to safeguarding data spread across systems, devices, and the Cloud. The key to addressing those risks and threats is building security into applications, as well as into interconnected devices, right from the start.” Gandhi feels that safety is a matter of design. He suggests, “For many fixed robots, physical guarding or safety sensors are provided. On the other hand, cobots or mobile robots have their own on-board sensors to ensure safety of humans that they work with. So, it’s a manageable concern.” Singhal explains that safety concerns are rising with larger adaptation of IIoT. Schneider Electric has a safety layer built in, with cyber security layers within processors. Also, they have increased their focus on machine & process safety with their products & solutions. Regarding job losses and upskilling, the views of vendors and some key users are quite interesting. “Automation does not imply lesser employment opportunities, because there will always be a need for newer skill sets to use and maintain the automated system and new opportunities will be created. Yes, a knowledgeable worker will get priority. Hence, reskilling the existing workforce is the one way to retain


quality manpower, while ensuring redeployment of semi-skilled manpower for other productive uses,” declares Phatak. Deshpande shares this sentiment. He offers, “Adding automation & robotics to the manufacturing sector need not be looked upon as an employment killer. It is possible to reskill the workforce in factories to adapt to new technologies. Considering the current trends and future challenges, few manufacturers have already started investing in training and skill development centres. These centres allow their employees to try complex concepts in industrial processes.” On the other hand, Gandhi acknowledges the job loss issue as a concern, and says, “We need to understand that automation automates activities and not jobs. The bedrock of a smart factory is the harmony between automation solutions and human beings.” As a user, Suresh provides a piece of advice. He proposes, “To overcome these hurdles/concerns, manufacturers should first implement these applications on a small scale. Once the small-scale model demonstrates that these applications have improved performance substantially whilst cutting costs, then you can apply them as best-practice models for other areas as well.” All things considered, the co-operation between men and machines is bound to not only stay, but, in fact, prosper in the future. And in doing so, it is also expected to have a significant impact on the industry in terms of its functioning, and also on the population in the way that it will revolutionise their lives.






TRANSFORMING BUSINESS EPICOR SOFTWARE CORPORATION HAS SOLUTIONS THAT CAN HELP MANUFACTURING COMPANIES MAKE FACT-BASED DECISIONS WITH ROBUST, BUILT-IN ANALYTICS FOR HIGHER PROFITABILITY. BY BINDU GOPAL RAO FOUNDED IN 1972, EPICOR SOFTWARE Corporation is a global business software company based in Austin, TX, USA. Its solutions are aimed at the manufacturing, distribution, retail and services industries. The company established an R&D facility in Bengaluru three years ago and expanded its local India operations in October 2017. To ensure that the Epicor brand is promoted to the Indian audience, the company recently ran a series of events together with a round table. The focus of the round table was to explain how companies can benefit from digital transformation. ERP MATTERS As a global organisation, it’s important to differentiate yourself and bridging the gap between niche and generic enterprise resource planning (ERP) solution provider is not easy. Epicor offers a solution with deep domain experience that is flexible, user-friendly, and cost-effective. Thiru Vengadam, regional vice president for Epicor in India, explained, “We pro-


MAY 2018 | Manufacturing Today

vide modern technology at a reasonable cost that can be implemented in less time than many of our competitors’ products.” The Epicor ERP solution is used extensively by both manufacturing and ancillary manufacturing industries. ENTERPRISE APPLICATIONS Manufacturers today are expanding beyond traditional markets. The supply chain is under pressure from coping with M&As, capital procurement and global expansion, and the need for innovation and speed is constantly increasing. David Mehok, chief financial officer for Epicor, commented, “When M&As happen, the key is to integrate people, technology, and systems and we focus on the ease of implementation for companies that are going through various types of acquisitions. It is important to be able to see one source of truth in terms of data and the ability to implement common platforms is central to making this happen. We want to make life easier for our users. Our ERP solutions

EPICOR ERP A single end-to-end software solution for business Epicor ERP is available on premises, hosted or in the cloud. The Epicor ERP solution supports the implementation of modern technologies like MES, IOT, Additive manufacturing, Analytics, Social Media, AI and Robotics, Virtual/Augmented Reality, and Industry 4.0. “The mid-market in India consists of over 300,000 businesses and at least 20,000 of them do not have an ERP solution in place but would really benefit for implementing one. Our integrated modular offering ensures that the system ties in all the business processes.,” said Vengadam. ADDITIVE MANUFACTURING 3D printing has come to the forefront and help ensure that there is less wastage. Cyber physical systems and platforms are happening and digital twining is becoming a focus. Epicor mobile access has a responsive design and personalised menu options with touch-friendly actions and dynamic content tiles. Access to reports and dashboards are also made avail-


provide the right information at the right time to help companies focus on growing their business and meeting regulatory requirements..” Digital transformation is being manifested through empowering employees, engaging customers, transforming products, and optimising operations. “Today’s customers gather a lot of intelligence and are well prepared before they meet us. This is why we need to continually transform our products so that we can meet the expectations of our customers both now and into the future,” said Vengadam. An Epicor survey of 2,500 businesses globally showed that 95 percent were optimistic about growth because they had a strong plan in place. An equal percentage are planning investments in technology to grow and 80 percent cite changes in customer needs in the digital space as having a critical impact on their ability to achieve business growth. The four forces disrupting the CFO role are digital (58 percent of finance leaders say they need to build their understanding of digital), data (57 percent of group CFOs believe that delivery of data and advanced analytics will be a critical capability for tomorrow’s function), risk and uncertainty (57 percent believe that risk management will be a critical capability in future) and stakeholder scrutiny and regulation (71 percent say they will increasingly be responsible for the ethics of decision making in support of their organisation’s purpose). “The problem of managing data is real and we want to help customers access real time data on key financial parameters whether it is working capital, NPA or Accounts Receivable Turnover,” added Mehok.

able on the mobile platform—in fact to any device and location. Technology now allows users to collaborate with all kinds of stakeholders—suppliers, employees and customers—and social media provides a platform for fast and easy exchange of information. “With a Cloud deployment choice it is important to understand that it is not always inexpensive. The cost of deploying a cloud solution, based on a number of studies done in India, can be more expensive within three years than an on premises solution. We are the only ERP vendor that has the same solution on both deployment choices, on premises or cloud and it is highly scalable,” said Vengadam. The Epicor ERP system has an enterprise search function as well as global compliancy functionality. In addition, DocStar ECM is a powerful enterprise content management and process automation solution designed to help manage and process documents in a secure environment, and Business Process Management is a built in tool for process management changes. “Operational Business Intelligence is the new school methodology that gives you information in real time so that decisions can be taken just in time as well. Corrective action is then possible immediately,” said Vengadam. Epicor data discovery and data analytics help with this data processing A full blown training system is available within the ERP system itself. The interactive round table session saw both finance professionals and IT heads exchange thoughts and views on what is needed by the manufacturing industry to make an ERP system more effective.

Manufacturing Today | MAY 2018



GEARED FOR MANUFACTURING IN AN EXCLUSIVE INTERVIEW WITH MANUFACTURING TODAY, DAVID MEHOK, CFO, AND THIRU VENGADAM, REGIONAL VP, INDIA, TELL US HOW EPICOR CAN HELP MANUFACTURING COMPANIES. BY BINDU GOPAL RAO Tell us the specific solutions you have for major sectors such as aerospace, automotive, medical devices and construction? Thiru: Our focus outside the USA is on manufacturing, especially discrete and supply chain management. Within the manufacturing industry there are several categories of business, with some being assemblers and others who build from scratch. Our solutions address the needs of industries like aerospace, automotive, medical devices and construction. For instance in aerospace we help provide International Traffic in Arms Regulations (ITAR) compliance or the volumes of documentation that is needed. Similarly for automotive OEMs we support the product lifecycle and product data management and the complete ERP cycle from planning to production, supply and service as well as supporting functions. We have a set of common business processes like quote to cash that are tailored to industry specific requirements. We can also extend the concept to ancillary suppliers and connect them with the main plant. David: In many manufacturing businesses there is a lot of information that is scattered across various systems and less than 1% of that is being used effectively. Coming from a CFO standpoint, when you have different systems with different information it is difficult to understand where the truth lies. One true source of data offers an advantage.

Thiru Vengadam


MAY 2018 | Manufacturing Today

You are looking at increasing your footprint in the manufacturing sector. What are your plans? David: We currently have 450 employees at our technology centre in Bangalore which is up from about 50 two years ago. We are now continuing to expand that centre to better support the global nature of our company.

What role does the Epicor Technology Centre play in terms of R&D and helping customers? David: We have people in the technology centre who are the brains behind product development. They help solve customers' problems using the technology we put inside the products and David Mehok embed in the systems. I oversee the finance, legal and IT, and tax teams. The feedback from customers help us to continually improve new releases. With the manufacturing industry looking at digital and Industry 4.0, how prepared are you with solutions and advice? David: This is exactly what we are focused on. We recently had our leadership team meeting which focused on the key strategic investments we will be making over the next 2-3 years to position the company over the next 5-10 years. Whether it is transformation like Industry 4.0 or revolution of big data, the bottom line is how companies can better utilise the information they generate which is a huge opportunity for us. The manufacturing sector in India, though IT savvy, has not been quick to adopt latest technology. What can propel them to do that? Thiru: Our key messages for the Epicor solutions are Fit, Ease and Growth. As far as ‘Growth’ is concerned we are not just building software, but want to support customer growth by building functionalities that will aid them. With ‘Ease’, our ERP solutions are easy to adopt and users benefit fast. We ensure that the software has deep industry specific functionality to make it ‘Fit’ for the purpose. We can easily train new users and are able to help manufacturers go live in as little as 3-4 months.

Key to the world of

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L-R: Vir Advani, MD, Blue Star, and Shishir Joshipura, MD and country head, SKF India.



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“We are keen to bring our expertise as well as technical know-how to the current and future design of new generation defence systems and products.” – MV Gowtama

“The partnership with HAL and Mahindra will enable us to optimise the full potential of both the sectors to deliver next-gen fighter planes.” – Pratyush Kumar


MAY 2018 | Manufacturing Today

ARTILLERY WITH INTELLIGENCE. THAT IS what the entire show was about. Nearly all 700 participants, of which nearly 155 were global players, had something clever to showcase at the 10th Edition of DefExpo 2018 held in Thiruvidenthai in Chennai. Self-propelled weapons systems, allweather systems that could revolve 3600 and fire multiple rounds under any weather conditions, ominous looking battle tanks that had large machine guns strapped to it, you name it and there were weapons on display. All for one purpose – defence and destruction. Immaterial of whether a country is in a state of war or not, it needs to maintain a stockpile of weapons and ammunition. And today's times demand that they be advanced and futuristic. It is not necessary for the country to manufacture it themselves. They could be open to purchasing the weapons from others who have the expertise, which is what most countries do. For several decades, India preferred to import sophisticated weapons and build little. Though we had the DRDO and Ordnance Factory Board (OFB), we liked to think that we didn’t have the expertise to make superior weapons inhouse. But since Mr Modi came to power, his constant chant of Make in India has compelled manu-

facturing companies to look at making more within the country. That also includes defence. BUILD THEM BIG Speaking at the inauguration, Nirmala Sitharaman, Minister of Defence, said that resources are not a problem for India’s defence programme. “Of the total capital expenditure, 33% will be spent on defence. There has been a consistent endeavour to avoid delays in procuring weapons systems. Our focus this year is to project India as a major hub of manufacturing of defence systems in the world by 2025.” Interestingly, this year the government had decided to reserve 50% of the space for Indian exhibitors, but the response was as high as 75% with many MSMEs participating overwhelmingly. The event also saw several high-profile MoUs signed between Indian companies and MNCs, and also between Indian companies. Bharat Electronics Limited (BEL) and Mahindra Defence Systems committed to a long-term partnership, to jointly address emerging opportunities in the domestic market under Make in India and the Export Promotion Policy of the Ministry of Defence to target the export market. SP Shukla, group president, aerospace


1 3


1. Kalyani Group's Bharat 52 is based on the requirements of the Indian Army. 2. The DRDO's exhibits included Nirbhay missile system with launcher, AUGV, MBT Arjun Mk-I tank, and Astra missile. 3. BEL Composite Shelter is designed and manufactured using advanced composite technologies having the lowest tare weight with equally good payload carrying capability.


MAY 2018 | Manufacturing Today

& defence, and chairman, Mahindra Defence, said, “Together we have capabilities in mobility, survivability, lethality, electronics and communications, making us ideal partners for new development as well as for upgrade of in service combat vehicles. This partnership can be grown not only to meet the requirements of Indian Armed Forces but also to target exports to other friendly countries.” MV Gowtama, CMD, BEL, said, “We are pleased to come together and keen to bring to the table our in-house expertise as well as technical know-how to the current and future design of new generation defence systems and products. There's a sense of confidence that the two of us will work together to contribute to indigenous defence production.” At its own booth, BEL invited the Chief of Army, General Bipin Rawat, to launch eight new products. The products launched were 100mbps radio, secure military wireless LAN, multi-function hand held

thermal imager, long range surveillance system, chemical agent monitor (CAM), multi-purpose reflex weapon sight, light weight composite shelter, and mine field recording system. From cutting-edge, multirole helicopters to proven military transport aircraft, Airbus displayed its wide-ranging defence capabilities. Visitors to the Airbus booth learnt about the combat-proven A330 MRTT, the only new generation aerial refueller in service today. Also on display was a scale model of the C295 military transport aircraft. “Airbus has been a trusted partner to the Indian armed forces for more than 50 years. We plan to develop a selfsustainable defence industrial ecosystem that will cater to the needs of India and, eventually, the armed forces around the world,” said Pierre de Bausset, president & MD, Airbus India. Airbus has teamed up with Mahindra Defence and is proposing both the AS565MBe Panther


and the H135M under the Naval Utility Helicopters (NUH) and the H225M under the Naval Multi Role Helicopters (NMRH) programmes, all with substantial transfers of technology and indigenisation compliant with ‘Make in India’ objectives. Similarly, Boeing India has signed an agreement with Hindustan Aeronautics (HAL), and Mahindra Defence to manufacture Super Hornet fighter aircraft in India. The companies will manufacture F/A-18 Super Hornet for India’s armed forces. The Super Hornet proposal is to build an entirely new and state-of-the-art production facility that can be utilised for other programmes like India’s Advance Medium Combat Aircraft (AMCA) programme. Pratyush Kumar, president, Boeing India, said, "The partnership with HAL and Mahindra will enable us to optimise the full potential of public and private sector to deliver next generation fighter planes. Together we can deliver an affordable, combat proven fighter platform for India, while adding growth to the Indian aerospace ecosystem." The Ordnance Factory Board (OFB) exhibited a new variant of the Mounted Gun System (MGS) armed with the Dhanush 155 mm/52 calibre gun. The indigenously developed MGS is the result of a two-year joint effort between OFB and Bharat Earth




Movers (BEML) to meet an Indian Army requirement of 814 MGS systems, with trials expecting to commence soon. The MGS is based on an 8x8 Tatra truck produced by BEML, which can attain maximum cross-country and road speeds of 30km/h and 80km/h respectively, with an unrefuelled cruising range of 1,000km. Main armament comprises the Dhanush 155 mm/52 calibre gun with a range of approximately 42km. The Kalyani Group highlighted its Bharat 52 155mm/52 calibre towed gun. The indigenously developed weapon is manufactured by its subsidiary, Bharat Forge, and is based on the requirements of the Indian Army. It completed mobility trials at the DRDO’s Vehicle Research and Development Establishment (VRDE) in Ahmednagar in 2015 and firing trials at the Ordnance Factories’ facility at CPE Itarsi in October 2017. According to Baba Kalyani, chairman, Kalyani Group, "The 15-tonne Bharat 52 has a firing range of about 41km, with a traverse of 35˚ to right and left, and elevation range of -3˚ to +72˚at a rate of 5˚/s. It also features a load assist system (LAS) that enables its crew to achieve rapid fires of 6 rds/min or a sustained rate of 42 rounds/ hr." Mahindra Defence and Aeronautics of Israel signed an MoU to partner for Naval Shipborne UAVs. Aeronautics and Mahindra will offer a UAV system which can be launched and recovered from Indian warships. The Aeronautics Orbiter 4 is an advanced multi-mission platform with an ability to carry and operate two different payloads simultaneously. With an open architecture, the Orbiter 4 can be specially adjusted to the needs of each mission. Among the different payloads the Orbiter 4 can carry are Maritime patrol radar (MPR), cellular interception sensor, satellite communication, Synthetic Aperture Radar (SAR), Automatic Identification System (AIS) and advanced electro-optic payload. Or-

“The 15-tonne Bharat 52 features a load assist system that enables its crew to achieve rapid fires of 6 rds/min.” – Baba Kalyani

4. Alpha Design Technologies showcased plenty of surveillance systems. 5. DRDO, Pune, had on display a massive canon reputed for long distance. 6. The key offerings of Bharat Dynamics is Akash SAM and ATGM such as Milan 2T, Konkurs M and INVAR to Indian Army.

Manufacturing Today | MAY 2018





PUTTING EXPERTISE TO USE R Shankar, CEO, TVS Logistics Services, has put his mind to gaining logistics contracts in aerospace & defence. Tell us some of the solutions you have for aerospace and defense. TVS Logistics has been working with the UK MoD for a decade now. We are also part of a consortium that recently won a contract worth £5bn with the UK MoD and will be executed over a 13 year period. TVS play a key role in data management, inventory management, procurement and product sourcing for the full range of military and non-military commodities required by the Ministry, including food, clothing, pharmaceuticals, medical equipment and general supplies – through a strong IT platform. This business is for all non-war equipment. They deal with vehicle spare parts and other commodities for both the Army, as well as the British Navy. Having done business in the European market, we thought it would be appropriate to explore possibilities of bringing in that capability to India and helping the Indian armed forces. What is the kind of infrastructure you will have to bring in before you pitch to the Indian defence sector? We have the capability. Our IT backbone is able to deliver a lot more. Besides this, we have Msys and other 3PL logistics services capability in India, which means transportation, material handling, warehousing, and any other value added services that the defence process may require. So a combination of these things is what we are trying to pitch and see how we can enhance the value to the defence forces.

7. Boeing displayed the Integrator. 8. The Chief of Army launched 8 products at the BEL booth.


MAY 2018 | Manufacturing Today

How does a logistics company pitch for a contract to the defence sector in India? It’s a long drawn process, because right now many defence organisations have their own logistics arm. We're in dialogue with various departments and divisions and it's too premature to comment as to what we will be doing.

Tell us about the backend technologies you have that you can make you stand out. We have custom developed an IT platform called Msys which has a suite of applications including Product Data Module, ERP, WMS, Business Intelligence, Demand & Forecast Planning; and Customer and Supplier portals. If you look at what the defence forces do in the UK, he places an order for the equipment on his handheld, and it gets delivered to him. That kind of technology is what we have and our experience with the defence forces has been varied, especially in the UK. Bagging a defence logistics contract has a long gestation period. Can you afford that kind of wait? We are here for the long haul. In India, the the private sector and the public sector have different ways of working. We are trying to see if we can make them change and any change process is long-drawn. As far as handling this sector is concerned, nobody outsources the core of defence. There is a government report which says the teeth to tail ratio should reduce in India. But the good part is that the government and the senior people are open to ideas. The Prime Minister is pursuing Make in India in a big manner. We also train our people to move with the times and besides the commercial practices that they have to follow, there is also the need to deliver savings in the marketplace, and implement our systems while helping out with clients.


biter 4 capabilities include maximum endurance of up to 24 hours, maximum take-off weight of 50kg, maximum flight altitude of 18,000ft while operating different payloads. From the new generation Gripen to ground combat weapons, Saab exhibited it all. Saab will display, for the first time in India, the Gripen Cockpit Simulator with its new Wide Angle Display (WAD). Besides Gripen, Saab products on display include RBS 70 NG VSHORAD, BAMSE SRSAM, Carl Gustaf M4 and AT4 with ammunitions. Robert Hewson, VP, head of communications, Saab Asia Pacific, said, "We are already well established in India. We have been making in India since the middle of the 1970s and our Carl-Gustaf infantry weapons family is a system that’s well known and well appreciated by the armed forces here. We have transferred that technology and been making on a significant scale in India for many decades. We are working with government agencies, Carl-Gustaf with OFB, and have several tie-ups with Indian agencies on different projects. For example, we have a future looking agreement with Adani for Gripen, and with the Kalyani Group on air defence products. We have worked with Ashok Leyland on potential air defence work." WHAT INDIA CAN DO India is the world's largest importer of arms, accounting for a whopping 13% of the global arms




trade during 2012-16. It takes 8-10 years for a defence contract to fructify, if not cancelled abruptly. It is important that the Aeronautics Commission identify 5-6 technologies critical to India. These could include advanced materials, stealth, avionics, sensors, cyber-security, precision guided missles, etc. An important factor is bringing down the procurement lead time to under three years. As news would have it, a significant change seems to be in the offing in India’s defence planning architecture with the Narendra Modi government deciding to establish an overarching defence planning committee (DPC) under the national security advisor. The aim is to leverage this cross-governmental body—comprising the chairman of the chiefs of staff committee, three service chiefs, the defence, expenditure and foreign secretaries—to enhance India’s ability to do some long-term strategising. The DPC is being tasked with drafting reports on “national security strategy, international defence engagement strategy, road map to build a defence manufacturing ecosystem, strategy to boost defence exports, and priority capability development plans”. Four subcommittees are to be created under the DPC to focus on policy and strategy, plans and capability development, defence diplomacy, and the defence manufacturing ecosystem. At a time when advances in technology are revolutionising warfare, India is still debating the need to move towards leaner force structures. India needs to cut the flab on an urgent basis as over half of the annual defence budget going to meet salary and pension requirements is clearly not sustainable. The priorities of India’s “Make In India” initiative and cumbersome defence procurement process will also have to be brought in sync with each other. India’s status as the world’s largest arms importer hardly does justice to its ambitions to emerge as a defence manufacturing hub. The debate on integration, both among the services headquarters, and between the services and the ministry of defence, continues unabated and should be concluded.

“We have capabilities in mobility, survivability, lethality, electronics and communications, making us ideal partners for new development.” – SP Shukla

9. Tata Aerospace displayed its latest VTOL mini-drone, that combines an electrically powered quadrotor for vertical lift. 10. The Russian booth had on display advanced helicopters for the Army and Navy. 11. The government stalls too showed off equipment and machinery for all the three Forces.

Manufacturing Today | MAY 2018





How big is India as a market and what is your current share of the market in the country? The current Indian market should be close to around Rs 3,000 crore, while our share of the market is currently 6%, which mainly comes from the automobile and two-wheeler segment, which constitute around 50% of our market share. Other segments including general engineering, defence & aerospace, medical, power, food industry etc., contribute to a certain level. When we started in 2010, the company turnover was only Rs 9 crore. After IMC took over and brought in new technology and products, we have begun to grow at a rapid pace. From a team of only seven people, we now have a team of 93 people across India, with close to 100 distributors working under us. We are working towards Mission 200 crore. So far, we have reached Rs 150 crore, and are hopeful that in the next year or so, we should cross the Rs 200 crore target that we have set. What are some of the crucial points on which Tungaloy India offers stiff competition to both its organised and unorganised sector competitors? Tungaloy spends well on its metallurgies. Hence, the basic metal that we use to make the carbide mixture is our strength. With IMC on board, the latest technologies required for new kinds of tools, has been shared with us. So it’s a lethal combination of extremely good technology and one of the strongest metallurgical powders, which works in our favour. As a result, we are catering to the organised sector players, directly or through our distributors. Our distributors cater to all segments, right from OEMs to the middle segment, and even a low segment. Thus, we've segmented the market in such a way that we have a distributor catering to each possible segment.


MAY 2018 | Manufacturing Today

How is the TungForce range of products performing in India? What are your plans to introduce new technologies or product innovations in India? TungForce was introduced because we saw a big change coming to India. Customers are more educated, and choosing to buy and invest in expensive machines. As a result, they now require high-quality tools to make optimum use of their machines. That is how the TungForce frontline was launched two years back, and it currently contributes around 25-30% of our sales. In fact, all the old products have been phased out and replaced with these new products, keeping in mind what India is aiming at now in terms of making faster and better. The TungForce range is specifically suited for that. Are you also working with the Government, especially on the defence front? Yes, we’re working with HAL, ordinance factories, and even PSUs like SAIL. Defence is on top of the Government’s agenda, further driven by the Make in India scheme. Thus, a lot of new projects are coming up, and we’re working on most of these projects. L1 is the biggest challenge that we have in this segment. While they are investing in good machines, they request for the cheapest possible inserts, which is possibly the biggest laggard in the working scenario. Despite this, we want to focus on providing solutions rather than competing on pricing, as we believe that the price does not matter once a solution is made available. Quality and precision in your business has to be impeccable. How does an organisation such as yours ensure quality through all your processes? As far as manufacturing is concerned, we are blessed that quality is maintained by the Japanese, so the product quality is the best possible. In addition, manpower is trained dedicatedly every year, both in India and Japan, to make sure that they provide the right service and value to their customers. The third important part is to ensure product delivery on time. For this, we have considerable stock stored at our warehouse in Mumbai, and also with our distributors, thus ensuring that the customer can immediately have the product delivered once they place an order. In essence, from the production to sales, we try to make sure that the critical path of quality and service is maintained.

VS ANAND, MD, CHEMETALL INDIA, HAS A STRONG FOCUSED APPROACH WHEN IT COMES TO DELIVERING INNOVATIVE PRODUCTS TO CUSTOMERS. make sure that our customers get maximum value from their investment in Chemetall technology. Our expert knowledge and premium support is backed by a well-staffed 'coolant management' laboratory with state-of-the-art analytical equipment. Our customers benefit from the exceptional value that our quality chemistry combined with customisable services and proven solutions provides to their business. Being a BASF company, innovation is key to our business. Our metalworking fluids have been awarded Frost & Sullivan ‘Best Practices Award’ for ‘new product innovation’ in 2014 and 2016.

What is the kind of customised technology and solutions you have for surface treatment? Chemetall has been in the business of metal surface treatment for over 150 years. We are the global leaders in surface treatment technologies and a onestop solution for all chemical treatments of metals. Chemetall is now part of BASF and our integrated portfolio of innovative products includes: Cut it: Coolants, cutting fluids, and lubricants Clean it: Cleaners and paint strippers Coat it: Corrosion preventives, surface treatment and rust inhibitors Control it: CODACS and non-destructive testing Conserve it: Energy savings technologies, water and wastewater treatment. Could you give us a glimpse into the quality of the fluids and also the after-sales support that you offer customers? Our metalworking fluids have been formulated to meet the diverse demands of the manufacturing industry. To meet the individual needs of our customer’s machining processes, we offer a broad portfolio of technologies that cool and lubricate the work tools and parts while purging chips and other debris from the workpiece. Our products are environmentally compatible and provide a safe working environment for the machine operator. Our technical experts evaluate customers‘ processes and make recommendations to improve or enhance production and the final product quality and



More customers demand cleaning solutions that are sustainable. How do you look at it? Besides the qualitative requirements, ecological criteria has become highly important. More customers seek environment-friendly cleaners. We offer customers an extensive selection of Gardoclean cleaners including alkaline, acid, electro and neutral cleaners, which are effective on a broad range of substrates. Gardoclean provides environmental compliance, energy savings, bath life extension, and other benefits. Tell us the manufacturing process of fluids. All our metalworking fluids are manufactured at our Pune and Chennai plants with state-of-the-art in-process control and analytical infrastructure. Local production of the fluids enables us to provide a high level of supply reliability. We even export some cutting fluids to many South Asian and Far East Asia countries. Our procurement process leverages our global presence for best-in-class raw materials that are carefully identified from an end-user benefit perspective. We explore opportunities to localise supply of global raw material and in the process work on building a sustainable business with our suppliers. What is the USP of your products? USP of our products is based on six points value proposition for customers: 1) Global specialists, 2) Locally available 3) Comprehensive and focused expert support 4) Integrated portfolio of innovative products, high standards, 5) Fast and accurate labs, and 6) Open collaboration for efficient process performance.

Manufacturing Today | MAY 2018



BREAKING THE MOULD THE DIE & MOULD INDIA 2018 EXHIBITION BROUGHT WITH IT NEW TECHNOLOGIES AND PRODUCTS, AND SAW A GREAT TURNOUT. BY TEAM MT THE 11TH BIENNIAL DIE & MOULD INDIA 2018 International Exhibition was held at its usual venue, Bombay Exhibition Centre, from April 11-14. The four-day event organised by TAGMA India showcased the latest products and solutions for the die & mould industry. The fair saw participation from 300 exhibitors from 19 countries presenting a variety of products and services for die & mould and other related industries. The number of visitors too increased two-fold as compared to the previous one. With a 15% increase


MAY 2018 | Manufacturing Today

in exhibitors and 45% increase in this venue, DMI 2018 resulted in a huge success. During the inauguration ceremony, Suresh P Prabhu, Minister of Commerce & Industry and Civil Aviation of India, addressed the gathering through a video message. “We are happy to see such an event related to die & mould being organised in Mumbai. TAGMA is doing a great job by encouraging the industry. Design is very important for manufacturing; it is a critical area and requires expertise. The industry has our support and we hope

CASTING THE DIE The die & mould industry needs the best surface finishing and there are several new-age technologies providing that. Adoption of high-speed machining and CAD technology enables reduction in production time and cost of producing high-precision surface finishes. VS Gopinath, associate chief manager, design, Godrej Tooling, says, “We prefer to get involved with the customer during the design of the component. It allows us optimise the cost of the component and offer good quality dies. We often interact with the R&D department and give them the measures needed to make the new kinds of components.” Most manufacturers take recourse to rapid tooling to reduce cycle times by nearly half as compared to conventional machining. This is executed by using conformal cooling, bimetal layering and better mould materials like aluminium, that allow quicker thermal conductivity inside the moulds. These rapid processes also ensure production of inserts and mould tooling in less than 48 hours. Rapid processes are also capable of producing modifications in the tool like undercuts or side-action, easily. Again, investing in R&D activities to cater to the enhancement of value


in newer products is a focus area. Anand Prakasam, country manager, EOS India, says, “We have three segments that we focus on: aerospace, dental, and medical. Here we are showcasing products printed from our metal technology that is mainly for injection moulding and die-casting. What you see here are predominantly for production and not prototypes. This solution offers the customer faster lead time, higher quality and higher tool life.” Mahantesh P, deputy general manager, forming tools India, Oerlikon Balzers, says, “Friction and wear are major factors limiting the performance and service life of tools. Our coatings and nitridings are among the most effective ways to make a significant difference to their operational performance. Special coatings with low friction coefficients and a low tendency to adhere and facilitate the machining of hardto-machine materials such as aluminium, titanium and magnesium alloys, and high-alloy steels, must be used by the manufacturing industry.” Speaking of why expertise matters in this industry, Ravindra More, manager, tool central planning, L&T Electrical & Automation, says, “We have capabilities that extend to design and manufacture of injection, compression and transfer moulds for engineering thermoplastics and thermosets. The tooling division also develops single and multi-cavity moulds with HRS for thermoplastics, single & multi-cavity moulds with cold manifold systems for thermosets.”

“What you see here are predominantly for production and not prototypes.” – Anand Prakasam


the new standards will help the industry and further provide a boost to the economy.” Jamshyd N Godrej, chairman of the Board of Godrej & Boyce Manufacturing Company, and the Chief Guest at Die & Mould 2018, added, “I have always propagated the idea of exhibitions. Exhibitions like DMI help people understand the kind of development that has happened in a particular industry.” Guest of Honour, Cabinet Minister, Maharashtra Legislative Assembly, Raj K Purohit said, “Die & Mould, also known as the mother industry, serves as the backbone of manufacturing. The same way TAGMA has the power to mould the future of the Indian die & mould industry. Exhibition of this stature will help the industry grow.”

2. The exhibition continued to pull a crowd even on the third day. 3. Visitors examine numerous equipment on display at the booths.


Manufacturing Today | MAY 2018



“A lot of new investments are happening and OEMs are also coming up with new projects.” – Sanjib Chakraborty

“We have always believed in empowering and enabling our industries in using the best and most advanced processes available on a global scale.” – Nickunj Shah

3. EOS displayed new equipment for production. 4. The Elo Dunia machine was up for live demonstration at the Nickunj stall. 5. Nickunj Group has entered into a strategic partnership with Malaysia's Elo Dunia Manufacturing (EDM).

BRINGING IN THE NEW The event saw a total of 31,256 visitors from diverse industries such as automotive, aerospace, die & mould, machine tools, heavy engineering, plastics, packaging, consumer goods, and so on. Given the varied profile of the attendees, there were a number of new-age technologies and latest products on display. Among others disruptive technologies, Additive Manufacturing seemed to be the flavour of the season. Hurco India, for instance, has fitted in a portable 3D printing head in their existing CNC-machine, in order to draw in customers who want to experiment with this technology at a lower price-point. This machine can then do both prototyping work using 3D printing and also do metal-cutting, and has already been received well. “We have received a huge response at the Die & Mould India 2018 show. The market is booming, and is bringing in customers – both old and new. A lot of new investments are happening and OEMs are also coming up with new projects. I think in the coming

3-4 years, the market will see more investments in areas like aerospace. That is where we are sensing that a lot of die & mould activity will happen, because that segment requires intricate and high-precision parts. Thus, a machine that is built and designed for die & mould can do much better machining for aerospace needs. Therefore, we are really excited about these prospects, and have been keeping very busy,” proclaims Sanjib Chakraborty, MD, Hurco India. Speaking of new opportunities, Nickunj Group has entered into a strategic partnership with a Malaysian graphite machine as well as machining stalwart – Elo Dunia Manufacturing (EDM). By leveraging on this partnership, Nickunj Group is looking to assist brands that deploy graphite machining. Nickunj Shah, MD, Nickunj Group, says, “This partnership allows us to bring the latest in CNC machining of graphite for our Indian clients. We have always believed in empowering and enabling our industries in using the best and most advanced processes available on a global scale. This will definitely put India on the map in terms of our production and manufacturing capabilities.” Every leading player has been doing something to stand apart from competition. Tungaloy India





MAY 2018 | Manufacturing Today


had introduced their TungForce range because they sensed that a major change was coming to India, with customers becoming more aware and choosing to invest in expensive machines. “As a result, they now require high-quality tools to make optimum use of their machines. If you buy a high-end machine, but do not run it at its optimum, you are actually losing money on it. That is how the TungForce frontline was launched two years back, and it currently contributes around 25-30% of our sales, which is a considerable value in the last two

years,” points out Jay Shah, MD, Tungaloy India. In fact, his company has phased out all the old products and replaced them with these new products. And change really is the only constant in this industry. Autodesk too has traded their old business model for a new, annual subscription-based model, which comes to customers at a lower cost, and hence, is an easier investment from a customer viewpoint. Just about a year on, it seems to be doing wonders for them, with customers returning to renew their subscriptions, and new customers joining the fold. In that sense, the exhibition could not have come at a better time for them. “Die & Mould is where we breathe our business. There is no too doubt that the right set of people are walking in and we’ve seen a pick-up over the duration of the exhibition in terms of footfalls and also relevant conversations. Hence, I would rate the turnout very high, this year. For us, the timing has been brilliant, because we just launched our 2019 version of our flagship product, PowerMill. It is a very good time to showcase this technology. And, most importantly, the business model transition is progressing well,” confesses Pankaj Gauba, head, digital manufacturing, India & Middle East, Autodesk India. All in all, the event left everyone involved content with the business generated and optimistic regarding future prospects.

“TungForce frontline was launched two years back, and it currently contributes around 2530% of our sales.” – Jay Shah





7TH SEPTEMBER 2018 THE WESTIN GURGAON, NEW DELHI For sponsorships, contact: Bibhor Srivastava,, +91 98204 39239 Sanjay Bhan,, +91 98457 22377 Hafeez Shaikh,, +91 98331 03611 For nominations, contact: Rahul Mishra,,+91 97689 79261 Amruta Mulye, +91 99309 36015



INDIVIDUAL CATEGORIES ♦ Plant Head of the Year ♦ Entrepreneur of the Year ♦ Next Generation Leader

AWARD CATEGORIES ♦ Excellence in Training & Skill Development

♦ Excellence in Innovation

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♦ Excellence in Human Resource

♦ Excellence in Safety

♦ Excellence in Customer Service

♦ Excellence in Supply Chain

♦ Excellence in CSR

♦ Excellence in Quality Development

♦ Excellence in Sustainability

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NOMINATIONS NOW OPEN To download the nomination forms, log on to:


AUGUST 4, 2018



IT IS BETTER FOR MANUFACTURING COMPANIES TO MOVE TO ADDITIVE MANUFACTURING AS IT SAVES IMMENSE COSTS ON DESIGNING AND CREATING PRODUCTS. BY BINDU GOPAL RAO IN INDIA, THE ADOPTION OF ADDITIVE manufacturing or 3D printing (or AM as it is popularly known) is increasing. The proof is in the figures — nearly 30 machines were sold last year. In 2015 and 2016 it was just four or five machines. But the need is growing. Small as well as large enterprises are taking advantage of additive manufacturing technology


MAY 2018 | Manufacturing Today

and even public sector companies are using additive manufacturing. Globally companies are using AM for production. But in India, it is largely used for prototyping. Incidentally additive manufacturing (AM) has been around for close to three decades and there has been a significant technology upgradation last few years.

FEATURE ADDITIVE MANUFACTURING “The one big advantage of AM is that irrespective of industries, it can cater to many industry verticals.” – Anand Prakasam

LOOKING BACK The AM technology has evolved from prototyping development. It has shifted to manufacturing. The machines themselves, the processing technologies and the materials have also evolved. Some of the areas are aerospace, dental and medical. “A lot of software is being developed in parallel. A robust ecosys-

tem has come up. It is not a standalone mechanism but can be included in the production chain. That has been the leap forward. The one big advantage of AM is that irrespective of industries, it can cater to many industry verticals. What was earlier done with 100 or 200 people, additive manufacturing can help achieve the same with four to five people,” says

“Because you can print complex shapes and parts, such as a part with a void inside, that gives an immense advantage over the traditional methods.” – Renuka Srinivasan

Manufacturing Today | MAY 2018




Anand Prakasam, country manager - India, ‎EOS GmbH India Branch Office.

“We are looking at In Process Monitoring where the machine provides real time in-process monitoring and is Industry 4.0 compliant and we have system called InfiniAM for this.” – Nayan Patel

1 & 2. Automatic three dimensional performs plastic modeling.



MAY 2018 | Manufacturing Today

DOING IT RIGHT Additive Manufacturing (AM) refers to a set of technologies that build 3D objects by adding materials layer-upon-layer of different kinds whether metal, concrete or plastic. Using 3D modeling software and machine equipment and layering material, the AM equipment reads in data from the CAD file and adds successive layers to fabricate a 3D object. AM hence includes a combination of Direct Digital Manufacturing (DDM), 3D Printing, Rapid Prototyping (RP), layered manufacturing and additive fabrication. Designers and analysts must have good understanding of manufacturing in AM space. More than any other manufacturing process, here, you are adding material – as you are adding material, there is sintering going on, there is cooling going on – all of this has an impact on the part you are printing. “So, in AM, the actual work has to begin at the design stage itself. One example could be, in metal printing. You may be looking at a few percentage points of distortion and you know there is likely to be some level of distortion while printing that needs to be factored into the design phase itself. You have to account for thermal behaviour and you come up with revised parts where the distortion effects are

minimal. Because you can print complex shapes and parts, such as a part with a void inside, that gives an immense advantage over the traditional methods. You can have a single tightly sintered part as against a loosely joined assembly of multiple parts. This not only improves the look and feel of the product but also the sturdiness and the life of the parts you make. This is possible with AM,” explains Renuka Srinivasan, director, SIMULIA WW Services, Dassault Systèmes. Sridhar Balaram, founder and MD, Intech DMLS, adds, “With respect to hardware, machines are becoming faster, smarter and bigger. As more lasers are being added to the system, the size of the platform has increased from 100mm to one-meter. Whereas for production, machines are settling at 400mm or 500mm. Coming to software, we can see advancements in increased reliability to ensure consistent part quality, likewise, with AM Simulation technology we will be able to reduce and eventually eliminate build failures and part distortions altogether.” Simultaneous printing of multiple parts is another application area for large format machines. The fundamental premise of AM is that as an effective solution that is also easy. “For example, in the aerospace sector, if they have to manufacture a part today based on a design, they have to follow a multi-step process such as tooling, fixtures, etc. It costs a lot and requires time. But with AM, if you have a design in hand, you can directly print the part you want. This reduces time, costs as well as number of operations. The customer can simply focus on the design itself than the manufacturing. AM is just a tool that prints as per your design,” says Prakasam. TECH TALK Newer technologies that are trending include DMLS, Direct Metal Deposition, Binder Jet, and Embedded technology. There is a three-fold innovation that can be observed in AM that includes hardware 3D printers, software that is enabling 3D printing as well as materials for 3D printing. Srinivasan adds, “We have



created a marketplace where an Indian company can sign up, pay charge, and connect with service providers who can help them with on-demand manufacturing of components. Now customers have access to over 600 machines and suppliers. They can get a quote online. They will 3D geometry and can scan these suppliers based on the kind of process and machines they have. They can send a request for a quote and based on the geometry, they can get the part they want to manufacture.” Adoption for production is happening in the medical sector especially customised medical implants. Likewise aerospace is another industry adopting this technology for production. “We are looking at In Process Monitoring where the machine provides real time in-process monitoring and is Industry 4.0 compliant and we have system called InfiniAM for this,” adds Nayan Patel, operations & technical manager, Renishaw. INNOVATION MATTERS Apart from laser sintering improvements, miniature desktop machines are coming in. Another hardware advancement is being seen in high temperature builds. “You build a platform of 1500 Celsius and we are now looking at building a platform for 4900 Celsius which addresses a lot of problems when you are using high strength materials like titanium. You will need this only for metal and metal parts are going to be put under stress to test the integrity of the part,” says Patel. New materials coming up include bio-compatible titanium for AM, aerospace approved aluminum as well as high nickel alloys. Guruprasad Rao, director & mentor, Imaginarium India, explains, “The software is getting geared for 3D printing. New file formats are coming in. 3MF and AMS are coming up as portable file formats and the future is going to be loaded with colour, encryp-

APART FROM LASER SINTERING IMPROVEMENTS, MINIATURE DESKTOP MACHINES ARE COMING IN. tion and expiry date properties. Material was a neglected area traditionally but in the last five years, there has been a lot of funding in research and material is going to lead to innovation. CNC and 3D printing are being combined as they can deliver many things not only faster but also cheaper. Digital manufacturing is the future and with CNC + Robots + 3D printing it will be a formidable force.” Intech has developed a software called AMOptoMet that allows customers to optimise the parameters of the machine for powder bed technology. It can print parts faster with an effective control over the density, have the flexibility to tweak parameters and optimise Micro alloys for enhanced properties. The software is equipped with machine learning for prediction accuracy, product traceability, and effective management. It increases productivity and optimises heat treatment cycles. The software is made available for the purchase either through the original manufacturer or from us directly” adds Balaram. In the recent past there is an increased interest in 3D printing. But as technology becomes patent-expired, costs comes down and material supply improves as generic materials become available, it will increase adoption of metals.

“CNC and 3D printing are being combined as they can deliver many things not only faster but also cheaper.” – Guruprasad Rao

3. Object printed on metal 3D printer. A model created in a laser sintering machine close-up.

Manufacturing Today | MAY 2018



8th June 2018 | The Westin Gurgaon, New Delhi



Industry Speakers

Hours of Networking


Senior Delegates Attending



Sudhir Kumar Jt. Advisor, Niti Aayog


B Anil Baliga Sr Vice President, VE Commecial Vehicles Ltd.


Ravindra Dayal Executive Director, Maruti Suzuki

Pradeep Tewari CEO, UNO Minda


Vipin Kumar Group CIO, Escorts

Jagdish Lomte VP IT, Thermax


Anand Maithani Head SCM & IT, Apollo Tyres

Ideate Innovate Interact

FOR BRANDING ENQUIRIES, CONTACT: SANJAY BHAN, Director, | +91 98457 22377 HAFEEZ SHAIKH, Business Head, | +91 98331 03611 NIDHI BHARDWAJ, Sponsorship Manager, | +91 84519 58719


CASE STUDY “The first advantage is that these products offer a better quality; secondly, they are economical; and thirdly, there is a wide range of products to choose from.” – Ashish Sethi

“We have fitted a highcapacity Ergo block technology line, which produces 750 bottles per minute. In fact, we are the only company in India to use this technology. Here, we are using the Motul Cimlube PAK 322.” – Gursewak Singh


1. Kandhari Beverages' Nabipur plant. 2. Kandhari Beverages has been using MotulTech’s range of products for around seven years now. 3. The Krones machine uses the Motul MPU 461 for centralised lubrication.


MAY 2018 | Manufacturing Today



KANDHARI BEVERAGES, AN AUTHORISED FRANCHISE BOTTLER FOR THE COCA-COLA COMPANY IN INDIA, HAS BENEFITTED GREATLY FROM THE USE OF MOTULTECH’S LUBRICANTS. CHANDIGARH-HEADQUARTERED KANDHARI Beverages is an authorised franchise bottler for The Coca-Cola Company in India to sell a range of beverages in the states of Himachal Pradesh, Chandigarh, parts of Punjab, Haryana and Jammu and Kashmir. Founded in 1993, its line of business includes the manufacture of aerated drinks, juices and packaged water. Operating from four manufacturing facilities, which are located in Nabipur (Punjab), Baddi (Himachal Pradesh), Saha (Haryana) and Samba (Jammu & Kashmir), the company happens to be the largest franchise bottler for Coca-Cola in India. At any given point of time, their complete manufacturing capacity is 5,895 bottles per minute, and they produce more than 120 SKUs. They have 12 warehouses. Hence, given the scale of their business, there is a great need to go in for the right kind of lubricants for smooth operations. In this regard, the company trusts the MotulTech brand of lubricants. “We have been using MotulTech’s greases, oils and lubricants in our company for various reasons. The first advantage is that these products offer a better quality; secondly, they are economical; and thirdly, there is a wide range of products to choose from,” says Ashish Sethi, production manager, Kandhari Beverages. MotulTech is the industrial lubricants division of the Motul group, a French industrial group specialising in high-performance lubricants for more than 160 years. The company is known for its innovation and the quality of its products. Kandhari Beverages has been using MotulTech’s range of products for around seven years now. The products used include Motul MPU 461; Motul CIMLUBE PAK 322; Motul TECH FG 2; Motul CIMLUBE HE 250 CL; Motul CIMLUBE FTF 502; Motul SAFCO RUBRIC SZ 68; Motul IRIX EP LXM 222; and Motul GEAR FG 220; as well as the Motul SZ 68 hydraulic oil. For instance, on their German-made Krones ma-


chine that has been recommended by Coca-Cola, Kandhari Beverages uses the Motul MPU 461 for centralised lubrication. “This machine is fitted with a centralised lubrication system, unlike machines that have distributors along different stations. We also use Motul Tech FG 2, a food-grade lubricant, which causes no harm to human beings even if mixed with food & beverage products. This is used at our filling machine distributer, which is a critical application,” states Gursewak Singh, factory manager, Kandhari Beverages. On the other hand, on their blow-moulding machine, where PET bottles are made, the Cimlube FTF 502 is used. The Cimlube HE 250 CL, a chain lubricant, is used for high-temperature applications over 2000C. “From 2016 onwards, we have fitted a high-capacity Ergo block technology line, which produces 750 bottles per minute. In fact, we are the only company in India to use this technology. Here, we are using the Motul Cimlube PAK 322,” says Singh. In addition, Kandhari Beverages plants are visited once in six months by the Coca-Cola representatives, in addition to auditors from their global audit team, in order to ensure that they comply with all the safety and quality checks that are mandated by the company. The lubricants to be used are also part of this assessment, therefore certificates are provided by MotulTech detailing the quality and safety of their products in use at these plants.

STUDER expands its product portfolio and introduces a new machine to the market – the favorit. This machine can be used universally and – because of the centre distance of 1600mm (63”) – can also handle long workpieces. The CNC universal cylindrical grinding machine is designed for grinding both single part and series production and can be fitted with automation. With various options such as measuring control, balancing system, contact detection and longitudinal positioning, it can be subsequently adapted to other grinding tasks. The favorit is a very reasonably priced machine. As with all STUDER cylindrical grinding machines, the proven machine bed made of solid Granitan ensures maximum precision, performance and safety. The full enclosure provides an optimal view of the grinding process. The wheelhead, which can be automatically positioned every 3°, can accommodate a belt-driven external and internal grinding spindle. Due to the practice-oriented STUDER grinding software, with its proven Studer- pictogramming, even less experienced us-



ers can programme grinding and dressing cycles quickly and efficiently. With the optionally available StuderGRIND software, special applications, such as profiling the grinding wheel for complex workpiece shapes, can be efficiently programmed. Development, production, assembly and testing of the STUDER products are process-oriented and comply with the strict guidelines of VDA 6.4 and ISO 9001. For more information, visit:


Industry-leading barcode reading and machine vision manufacturer OMRON Microscan introduces two new industrial code readers: the HS-360X, an ultra-rugged DPM handheld fit for automotive and heavy industrial applications, and the MicroHAWK ID-45, a perfect match for DPM applications in electronics and medical device manufacturing.

Both readers are optimised to capture the most challenging Direct Part Marks (DPMs) on all sorts of surfaces. Curved, shiny and irregular substrates pose zero problems for the advanced X-Mode decoding algorithms inside the HS-360X and the MicroHAWK ID45. Decoding speed is rapid-fire for dot-peened, laser-etched and ink-jetted codes regardless of size, density or contrast. Perfect for DPM applications in the automotive and heavy industry, the HS-360X demonstrates exceptional durability and shock resistance. Waterproof, dust-proof and capable of withstanding multiple drops to concrete, it’s built to last long in the harshest work environments. A 3100-mAh lithium ion battery coupled with the industry’s only on-board battery gauge supports extreme efficiency with 56% more scans per charge versus competing handhelds. Operators can also enjoy increased flexibility and easy setup through WebLinkPC. WebLink is also the force behind the ID-45’s intuitive plug-andplay setup. The reader integrates seamlessly into production lines for electronics, medical device manufacturing and similar industries, while its extensive array of 24 LEDs makes it brighter than previous generations of MicroHAWK. For more information, visit:

Manufacturing Today | MAY 2018






Turning and gear hobbing machine with automation all from one source.


Process description: Soft turning the 1st side, soft turning the 2nd side, gear hobbing. Turnkey solutions for the complete line.

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Modular machine integrated with automation. Machine concept perfect for line formation.


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Less operators required and machine maintenance made easy.


The TrackMotion automation system performs the complete transport of the part, including rotation.


The use of stacker pallets allows autonomous operation for hours.

Short travel times for loading and machining, resulting in the shortest possible cycle times.

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Proximity Switch Proximity Switch to prevent collisions. to prevent collisions.

Touchscreen Touchscreen

Enables communication with communication the Enables gripper as well as teachingwith the gripper asvarious well as teaching or switching to or switching operation modes. to various operation modes.

Tactile Sensor System Sensor For Tactile on-time detection and System on-time detection diffFor erentiation betweenand workpiece and humans . differentiation between workpiece and humans.

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for detecting the surroundings, Mounted between the fingers difffor erentiating detectingand the surroundings, searching for objects.and differentiating

The first intelligent and safe HRC intelligent Gripper on and the Market The first safe Collaborative for every application. HRC Gripper on the Market For every cobot. Collaborative for every application. For every cobot.

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24.05.17 14:56

Š 2018 SCHUNK GmbH & Co. KG

Š 2017 SCHUNK GmbH & Co. KG

searching for objects.

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Mt 01 05 2018  

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